The overlooked risks in old agricultural buildings and machinery sheds

Alex Cormack outlines the often-overlooked structural, environmental and safety risks in older farm buildings and explains why proactive inspections and robust maintenance are essential.

Many barns, machinery sheds and workshops on farmland have stood for decades, remaining central to day-to-day operations.

Familiarity, however, can mask age-related deterioration.

Over time, these buildings are invariably adapted and repurposed to suit evolving agricultural practices, often without the upgrades needed to keep pace. As a result, buildings that were once fit for purpose now face demands far beyond their original design.

Here, we share the common issues and hazards found in ageing agricultural buildings and the steps rural businesses should take to manage them effectively.

Structural decline

As with many older buildings, farming structures may look sturdy from the outside, but decades of wear could be unknowingly taking its toll.

Steel frames can corrode, out of sight, while timber beams can soften and rot from leaks. Blockwork, meanwhile, could be crumbling internally with each freeze-thaw cycle and asbestos-cement roofing can be becoming increasingly brittle.

These vulnerabilities are being exacerbated by climate change, with storms becoming more frequent and severe. Heavy rainfall can saturate ageing materials, strong winds can loosen weakened frames and rapid temperature swings can widen cracks.

Many agricultural buildings, originally constructed for small vehicles and light equipment, now also have to contend with large tractors and machinery. When this modern, oversized machinery sits or moves through an older building, it can place extra strain on the structure. Doors and beams can be overloaded, existing weaknesses can be made worse by excessive vibrations while impact damage is almost expected when moving the machines.

The consequences can be costly. Structural failures often require urgent repairs and can interrupt operations, making it essential to undertake proactive inspections before issues impact profitability.

Environmental, storage and regulatory hazards

Older buildings can also present environmental risks.

The deterioration and failure of aging tanks or other facilities can lead to hazardous substances escaping, causing pollution and the risk of heavy fines.

During renovations and demolitions legacy hazards, from buried fuel tanks and old waste disposal areas to chemicals and building materials such as lead paint and asbestos, can also unexpectedly surface, calling for complex and costly remediation.

These risks highlight the importance of reviewing storage areas regularly and seeking advice before carrying out groundworks or renovation.

Electrical fire hazards  

Outdated electrical systems that have been frequently modified or repaired over the years can easily become fire risks.

Similarly, overloaded circuits can push wiring far beyond the bounds of what it can safely deliver.

Dust, cluttered workspaces and poor ventilation can create an environment where a short circuit or cable that is overheating can quickly lead to fire.

When it comes to their electrical wiring, farmers can ill-afford to be complacent.

An electrician should be commissioned to conduct an Electrical Installation Condition Report (EICR) on every ageing building to identify faults and ensure circuits are in good condition.

Machinery risks

Machinery may appear to be in good working order, but without the right checks, it can quickly become one of the most dangerous elements of an ageing building.

Equipment that falls under LOLER, PUWER and PSSR must be examined regularly. Inspections, however, can often fall by the wayside when machinery has been left stationary for years or used only occasionally. This not only endangers farm workers – it also exposes businesses to legal action.

Farmers should implement a documented maintenance schedule, ensuring every single item adheres to legal requirements regardless of age.

People and behaviour risks

The interiors of older buildings can often be a cause for concern too.

Poor lighting, uneven flooring, awkward layouts and cramped storage areas can make it harder for staff to work safely, increasing the risk of accidents and injuries.

Habits, however, become entrenched over time and staff will often adapt to conditions, with familiarity obscuring obvious hazards.

Legislation, such as the Health and Safety at Work Act 1974, means employers have a legal and moral duty of care to make the workplace safe for employees.

Taking the time to review lighting, layout, storage and access points can help to prevent injuries and ensure safety standards are met.

Safeguarding operations

Ageing agricultural buildings can present a wide variety of risks and staying on top of them is essential to keep farms running smoothly.

One fault can trigger unexpected downtime, costly emergency repairs, pollution incidents, equipment breakdowns or even regulatory action.

Insurers can also scrutinise ageing buildings more closely, potentially leading to higher premiums.

Proactive, well-structured risk management is essential. Addressing risks early and implementing regular inspections will help safeguard people and assets, leading to a reduction in costly operational disruption.

ENDS

IMPORTANT NOTE: This information sheet has been prepared by Lycetts and reflects information reviewed by Lycetts at the time of its publication.

Accordingly, account must always be taken of any relevant changes in law, policy or other circumstances since that time. It is for general information only and must never be relied upon as any substitute for appropriate professional advice, which should always be taken in any situation in which financial or other interests may be at stake.

This content is for general information purposes only and should not be construed as financial or insurance advice. Lycetts and its employees accept no liability for any errors or omissions.